INSTALLATION INSTRUCTIONS Split System Heat Pump &

INSTALLATION INSTRUCTIONS
13 SEER
Split System Heat Pump & Air Conditioner
1.5-5 Tons
R410A
NOTE: Appearance of unit may vary.
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION
WARNING
These instructions are intended as an aid to qualified
licensed service personnel for proper installation, adjustment and operation of this unit. Read these instructions
thoroughly before attempting installation or operation.
Failure to follow these instructions may result in improper
installation, adjustment, service or maintenance possibly
resulting in fire, electrical shock, property damage,
personal injury or death.
DO NOT DESTROY THIS MANUAL
Please read carefully and keep in a safe place for future reference by a serviceman.
TABLE OF CONTENTS
2
This document is customer property and is to remain with this unit.
These instructions do not cover all the different variations of systems nor does
it provide for every possible contingency to be met in connection with installation.
All phases of this installation must comply with NATIONAL, STATE, AND LOCAL
CODES. If additional information is required please contact your local distributor.
1.0 SAFETY
This is a safety alert symbol. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury.
This is an attention alert symbol. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury.
Understand and pay particular attention to the signal words DANGER, WARNING, or
CAUTION.
DANGER indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.
WARNING indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.
CAUTION indicates a potentially hazardous situation, which, if not avoided may result
in minor or moderate injury. It is also used to alert against unsafe practices and hazards
involving only property damage.
WARNING
Improper installation may create a condition where the operation of the product
could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Refer to this manual for assistance or for additional
information, consult a qualified contractor, installer or service agency.
CAUTION
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not
limited to building, electrical, and mechanical codes.
WARNING
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death
or property damage.
A fire or electrical hazard may result causing property damage, personal injury
or loss of life.
CAUTION
If using existing refrigerant lines make certain that all joints are brazed, not
soldered.
CAUTION
Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning.
3
1.1 INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit.
If damage is evident, the extent of the damage should be noted on the carrier's delivery
receipt. A separate request for inspection by the carrier's agent should be made in
writing. See Local distributor for more information.
Requirements For Installing/Servicing R410A Equipment
Gauge sets, hoses, refrigerant containers, and recovery system must be designed
to handle the POE or PVE type oils.
Manifold sets should be 800 PSIG high side and 250 PSIG low side with 550 PSIG
Iow side restart.
All hoses must have a 700 PSIG service pressure rating.
Leak detectors should be designed to detect R410A.
Recovery equipment (including refrigerant recovery containers) must be specifically designed to handle R410A.
Do not use an R-22 TXV.
Good Refrigeration practices require the installation of a field supplied liquid line
drier, as shown in Fig.1.
NOTE :
It will be more convenient to open
the Service valve after removing
the Underside Clapboard.
LARGE SERVICE VALVE
SMALL SERVICE VALVE
LIQUID-LINE FILTER-DRIER
FIELD SUPPLIED AND INSTALLED
Fig.1 Filter-Drier installation
1.2 LIMITATIONS
The unit should be installed in accordance with all National, State, and Local Safety
Codes and the limitations listed below:
1.Limitations for the indoor unit, coil and appropriate accessories must also be observed.
2.The outdoor unit must not be installed with any duct work in the air stream. The outdoor fan is
the propeller type and is not designed to operate against any additional external static
pressure.
3.The maximum and minimum conditions for operation must be observed to assure a system
that will give maximum performance with minimum service.
4.This unit is not designed to operate with a low ambient kit. Do not modify the control system
to operate with any kind of Iow ambient kit.
5.The maximum allowable line length for this product is 150 feet (Just for scroll compressor).
2.0 GENERAL
The outdoor units are designed to be connected to a matching indoor coil with braze
connect lines. Units are factory charged with refrigerant for a matching indoor coil
plus 15 feet of field supplied lines.
Matching indoor coils are available with a thermostatic expansion valve or an orifice
for the most common usage. The orifice size and/or refrigerant charge may need to
be changed for some indoor-outdoor unit combinations, elevation differences or
total line lengths.
4
W
AIR DISCHARGE: ALLOW 60”
MINIMUM CLEARANCE.
AIR INLETS
LOUVERED PANELS
ALLOW 18”
MINIMUM
CLEARANCE
SERVICE ACCESS
ALLOW 24” CLEARANCE
NOTE: GRILL APPEARANCE
MAY VARY.
POWER WIRING
SEE DETAIL A
DETAIL A
CONTROL WIRING
7/8” (22.2mm)
KNOCKOUT
1-11/32” (34.5mm)
HOLE
1-3/32” (27.8mm)
SERVICE
FITTING
LIQUID LINE
CONNECTION
DIMENSIONAL DATA
MODEL SIZE
AC
18T/L,24L
18C,24T/C
30T
30C/L,36L
36C
42C/L
48C/L
60C/L
FIG.2 DIMENSIONS
Dimensions (Inches)
"H" in. [mm]
24-15/16[633]
18C/T,24C/T 24-15/16[633]
30C/T,36C 24-15/16[633]
24-15/16[633]
29-7/8[759]
42C
33-3/16[843]
29-7/8[759]
48C
33-3/16[843]
60C
HP
SERVICE
SUCTION LINE FITTING
CONNECTION
"W" in. [mm]
21-7/8[554]
23-5/8[600]
28[710]
29-1/8[740]
28[710]
29-1/8[740]
28[710]
29-1/8[740]
Refrigerant Connection
Service Valve Size
"L" in. [mm] Liquid in. Suction in.
21-7/8[554]
3/8
3/4
3/8
23-5/8[600]
3/4
28[710]
3/4
3/8
29-1/8[740]
3/4
3/8
28[710]
3/4
3/8
29-1/8[740]
3/4
3/8
28[710]
7/8
3/8
29-1/8[740]
7/8
3/8
NOTES: 1. AC: Air Conditioner; HP: Heat Pump;
2.T: Toshiba Compressor; C: Copeland Compressor; L: LG Compressor.
5
3.0 UNIT INSTALLATION
3.1 LOCATION
Before starting the installation, select and check the suitability of the location for both
the indoor and outdoor unit. Observe all limitations and clearance requirements. The
outdoor unit must have sufficient clearance for air entrance to the condenser coil, for air
discharge and for service access. See Fig.2
NOTE
For multiple unit installations, units must be spaced a minimum of 18 inches
apart. (Coil face to coil face.)
If the unit is to be installed on a hot sun exposed roof or a black-topped ground area, the
unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit.
Provide an adequate structural support.
3.2 GROUND INSTALLATION
The unit may be installed at ground level on a solid base that will not shift or settle, causing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in
Fig.2 and install the unit in a level position.
Normal operating sound levels may be objectionable if the unit is placed directly under
windows of certain rooms (bedrooms, study, etc.).
Top of unit discharge area must be unrestricted for at least 60 inches above the unit.
WARNING
The outdoor unit should not be installed in an area where mud or ice could cause
personal injury or system damage.
Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in
areas where there will be snow accumulation. Check the local weather bureau for the
expected snow accumulation in your area. Isolate the unit from rain gutters to avoid any
possible wash out of the foundation.
3.3 ROOF INSTALLATION
When installing units on a roof, the structure must be capable of supporting the total
weight of the unit, including a padded frame unit, rails, etc., which should be used to
minimize the transmission of sound or vibration into the conditioned space.
3.4 UNIT PLACEMENT
1.
2.
3.
4.
Provide a base in the pre-determined location.
Remove the shipping carton and inspect for possible damage.
Compressor tie-down nuts should remain tightened.
Position the unit on the base provided.
CAUTION
This system uses R410A refrigerant which operates at higher pressure than
R-22. No other refrigerant may be used in this system. Gauge sets, hoses,
refrigerant containers, and recovery system must be designed to handle
R410A. If you are unsure, consult the equipment manufacturer.
6
The outdoor unit must be connected to the indoor coil using field supplied refrigerant
grade copper tubing that is internally clean and dry. Units should be installed only with
the tubing sizes for approved system combinations. The refrigerant charge shown in
the nameplate is for standard size interconnecting liquid line lengths up to 15 feet.
NOTE
Using a larger than specified line size could result in oil return problems. Using a
too small line will result in loss of capacity and other problems caused by insufficient refrigerant flow. Slope horizontal suction lines at least 1" every 20 feet
toward the outdoor unit to facilitate proper oil return.
3.5 UNIT MOUNTING
If elevating the heat pump, either on a flat roof or on a slab, observe the following guidelines.
1. The base pan provided elevates the heat pump 2” above the base pad.
2. If elevating a unit on a flat roof , use 4”× 4”(or equivalent) stringers
positioned to distribute unit weight evenly and prevent noise and vibration (See Fig.3).
NOTE:Do not block drain openings shown in Fig.3.
3. If unit must be elevated because of anticipated snow fall, secure unit and
elevating stand such that unit and/or stand will not tip over or fall off.
NOTE: To tie down unit, see 3.6.
BASE PAN (BOTTOM VIEW) DO NOT
OBSTRUCT DRAIN HOLES
(SHADED)
BASE PAD
(CONCRETE OR
OTHER SUITABLE
MATERIAL)
ELEVATION ABOVE ANTICIPATED
SNOW IS NECESSARY
Fig.3 RECOMMENDED ELEVATED INSTALLATION
7
3.6 FACTORY-PREFERRED TIE-DOWN METHOD
Step 1: Prior to installing clear pad of debris.
IMPORTANT
Then cement pad must meet local codes and must be the proper thickness to
accommodate fasteners.
Step 2: Center and level unit onto pad.
Step 3: Using field supplied L-shaped bracket to locate holes on concrete and drill pilot
holes which is at least 1/4” deeper than fastener being used.
IMPORTANT
Self drilling screws to base pan should not exceed 3/8” long to avoid damaging
coil.
Step 4: Using conventional practices to install brackets, tighten concrete fasteners and
self-tapping screws (See Fig.4).
NOTE
NOTE: 1. One bracket for each side. For extra stability, 2 brackets for each side.
2. Do not over-tighten the concrete fastener to avoid weakening the concrete.
IMPORTANT NOTE:
These instructions are intended to provide a method to tie-down system to cement slab
as a securing procedure for high wind areas. It is recommended to check Local Codes
for tie-down methods and protocols.
The dimension see FIG.2
SEE DETAIL B
Brackets:
2” width, 1/16” thickness,
height as required.
Available from distributor
or in market place.
#7 X 3/8” Self Tapping Screws
(Don’t Exceed 3/8” long)
DETAIL B
1/4” Χ 1-1/2” Hex Washer Head Concrete Screws
(3/16” Pilot Hole Needed. Pilot Hole Should Be1/4” Deeper
Than The Fastener Embedment)
Fig.4 PREFERRED
TIE-DOWN
METHOD
REQUIRED
PARTS
LIST
8
3.7 PRECAUTIONS DURING LINE INSTALLATION
1. Install the lines with as few bends as possible. Care must be taken not to damage
the couplings or kink the tubing. Use clean hard drawn copper tubing where no
appreciable amount of bending around obstruction is necessary, if soft copper must
be used, care must be taken to avoid sharp bends which may cause a restriction.
2. The lines should be installed so that they will not obstruct service access to the coil,
air handling system or filter.
3. Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure.
4. The suction line must be insulated. Tape and suspend the refrigerant lines as shown.
DO NOT allow tube metal-to-metal contact. See Fig.5.
5. Use PVC piping as a conduit for all underground installations as shown in Fig.6.
Buried lines should be kept as short as possible to minimize the build up of liquid
refrigerant in the suction line during long periods of shutdown.
6. Pack a sealing material such as perma gum around refrigerant lines where they
penetrate a wall to reduce vibration and to retain some flexibility.
Suggested
optional
Sheet Metal Hanger
Insulated Suction Line
Tape
Incorrect
Insulated Liquid Line
Fig.5 Tubing Hanger
Fig.6 Underground Installation
9
WEATHERPROOF
DISCONNECT
SWITCH
TO
POWER
SUPPLY
TO
24V c
ontro
INDOOR
l sign
al
BLOWER
TO
COIL
Seal opening(s) with
permagum or equivalent
NOTE:All outdoor wiring must be weather proof
Fig.7 Typical Installation
3.8 PRECAUTIONS DURING BRAZING OF LINES
All outdoor unit and evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO
NOT use soft solder. The outdoor units have reusable service valves on both the liquid
and suction connections. The total system refrigerant charge is retained within the
outdoor unit during shipping and installation. The reusable service valves are provided
to evacuate and charge per this instruction.
Serious service problems can be avoided by taking adequate precautions to assure an
internally clean and dry system.
CAUTION
Dry nitrogen should always be supplied through the tubing while it is being
brazed, because the temperature required is high enough to cause oxidation
of the copper unless an inert atmosphere is provide. The flow of dry nitrogen
should continue until the joint has cooled. Always use a pressure regulator
and safety valve to insure that only low pressure dry nitrogen is introduced into
the tubing.Only a small flow is necessary to displace air and prevent oxidation.
3.9 PRECAUTIONS DURING BRAZING SERVICE VALVE
Precautions should be taken to prevent heat damage to service valve by wrapping a wet
rag around it as shown in Fig.8. Also, protect all painted surfaces, insulation, during
brazing. After brazing cool joint with wet rag.
The valve can be opened by removing the plunger cap and fully inserting a hex wrench
into the stem and backing out counter-clockwise until valve stem just touches the chamfered retaining wall.
10
Connect the refrigerant lines using the following procedure:
1. Remove the cap and Schrader core from both the liquid and suction service valve
service ports at the outdoor unit. Connect Iow pressure nitrogen to the liquid line
service port.
wet rag
service valve
Fig.8 Heat Protection
2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to wrap the valve
body with a wet rag. Allow the nitrogen to continue flowing. Refer to the Tabular Data
Sheet for proper liquid line sizing.
3. Carefully remove the rubber plugs from the evaporator liquid and suction connections
at the indoor coil.
4. Braze the liquid line to the evaporator liquid connection. Nitrogen should be flowing
through the evaporator coil.
5. Slide the plastic cap away from the suction connection at the indoor coil. Braze the
suction line to the evaporator suction connection. Refer to the Table 1 for proper
suction line sizing.
6. Protect the suction valve with a wet rag and braze the suction line connection to the
outdoor unit. The nitrogen flow should be exiting the system from the suction service
port connection. After this connection has cooled, remove the nitrogen source from
the liquid fitting service port.
7. Replace the Schrader core in the liquid and suction valves.
8. Leak test all refrigerant piping connections including the service port flare caps to be
sure they are leak tight. DO NOT OVER TIGHTEN (between 40 and 60 inch -lbs.
maximum).
9. Evacuate the suction line, evaporator, and the liquid line, to 350 microns or less.
Table 1: Recommended Liquid and Suction Tube Diameters (ln.)
LIQUID
MODEL SIZE
SUCTION
Tube Diameter
Tube Diameter
18
3/8
3/4
24
3/8
3/4
30
3/8
3/4
36
3/8
3/4
42
3/8
3/4
48
3/8
7/8
60
3/8
7/8
11
10. Replace cap on service ports. Do not remove the flare caps from the service ports
except when necessary for servicing the system.
11. Release the refrigerant charge into the system. Open both the liquid and suction
valves by removing the plunger cap and with an hex wrench back out counter
-clockwise until valve stem just touches the chamfered retaining wall.
12. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat).
Cap must be replaced to prevent leaks.
WARNING
Never attempt to repair any brazed connections while the system is under pressure. Personal injury could result.
See "System Charge" section for checking and recording system charge.
4.0 INTERCONNECTING TUBING
4.1 SUCTION AND LIQUID LINES
Keep all lines sealed until connection is made.
Make connections at the indoor coil first.
Refer to Line Size Information in Tables 2 and 3 for correct size and multipliers to be
used to determine capacity for various suction line diameters and lengths of run. The
losses due to the lines being exposed to outdoor conditions are not included.
The factory refrigerant charge in the outdoor unit is sufficient for 15 feet of standard
size interconnecting liquid line. Calculate actual charge required with installed liquid
line size and length as below.
1/4” ± .2 oz. per foot
5/16” ± .4 oz. per foot
3/8” ± .6 oz. per foot
1/2” ± 1.2 oz. per foot
4.2 MAXIMUM LENGTH OF LINES
The maximum length of interconnecting line is 150 feet (Just for scroll compressor).
Always use the shortest length possible with a minimum number of bends.
NOTE: Excessively long refrigerant lines cause loss of equipment capacity.
4.3 VERTICAL LIFT
Keep the vertical lift to a minimum. Use the following guidelines when installing
the unit:
1. DO NOT exceed the vertical lift as indicated on Table 3.
2. It is recommended to use the smallest liquid line size permitted to minimize sys tem charge which will maximize compressor reliability.
3. Table 3 may be used for sizing horizontal runs.
5.0 EVACUATION
It will be necessary to evacuate the system to 350 microns or less. If a leak is
suspected, leak test with dry nitrogen to locate the leak. Repair the leak and test again.
To verify that the system has no leaks, simply close the valve to the vacuum pump
suction to isolate the pump and hold the system under vacuum. Watch the micron
gauge for a few minutes. If the micron gauge indicates a steady and continuous rise,
it's an indication of a leak. If the gauge shows a rise, then levels off after a few minutes
and remains fairly constant, its an indication that the system is leak free but still
contains moisture and may require further evacuation if the reading is above 350
microns.
12
LINE SIZING
TABLE 2: SUCTION LINE LENGTH/SIZE VS CAPACITY MULTIPLIER(R410A)
1 1/2 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
2 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
2 1/2 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
3 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
3 1/2 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
4 Ton
7/8" O.D.
3/4 Opt.
7/8* Std.
5 Ton
7/8" O.D.
1 1/8 Opt.
7/8* Std.
Optional
Standard
Optional
Standard
Optional
Standard
1.00
1.00
0.97
0.98
0.94
0.95
1.00
1.00
0.97
0.98
0.94
0.95
1.00
1.00
0.97
0.98
0.94
0.96
1.00
1.00
0.97
0.99
0.94
0.97
1.00
1.00
0.98
0.98
0.95
0.97
1.00
1.00
0.98
0.98
0.95
0.97
1.00
0.99
0.99
0.98
0.98
0.94
Optional
Standard
0.90
0.92
0.90
0.92
0.90
0.93
0.90
0.96
0.91
0.96
0.92
0.96
0.97
0.90
Model Size
Suction Line Connection Size
Suction Line Run-Feet
25'
50'
100'
150'
NOTES:
* Standard size
Using suction line larger than shown in chart will result in poor oil return and is not recommended.
TABLE 3 :LIQUID LINE SIZE (R410A)
Model Size
1 1/2 Ton
Line Size
Connection Size
(Inch O.D.)
3/8"
Compressor
Type
Scroll
Rotary
2 Ton
3/8"
Scroll
Rotary
2 1/2 Ton
3/8"
Scroll
Rotary
3 Ton
3/8"
Scroll
3 1/2 Ton
3/8"
Scroll
4 Ton
3/8"
Scroll
5 Ton
3/8"
Scroll
Line Size
Connection And
Line Size
(Inch O.D.)
1/4
5/16
3/8*
3/8*
1/4
5/16
3/8*
3/8*
1/4
5/16
3/8*
3/8*
5/16
3/8*
5/16
3/8*
3/8*
1/2
3/8*
1/2
Liquid Line Size
Outdoor unit above or below indoor coil
Total Equivalent Length - Feet
25
50
75
100
125
Maximum Vertical Separation - Feet
150
25
25
25
25
23
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
40
50
50
30
N/A
36
50
30
N/A
49
50
30
50
50
23
50
46
50
50
50
N/A
30
30
N/A
N/A
9
30
N/A
N/A
6
30
N/A
N/A
30
N/A
24
15
30
20
30
25
60
60
30
N/A
29
60
30
N/A
38
60
30
37
60
4
43
38
56
56
60
9
58
60
27
N/A
23
60
24
N/A
27
60
22
22
60
N/A
36
30
55
44
60
N/A
40
40
N/A
N/A
16
40
N/A
N/A
17
40
N/A
7
40
N/A
30
22
40
32
40
NOTES:
* Standard line size
N/A Application not recommended.
13
6.0 ELECTRICAL CONNECTIONS
6.1 GENERAL INFORMATION & GROUNDING
Check the electrical supply to be sure that it meets the values specified on the unit
nameplate and wiring label.
Power wiring, control (Iow voltage) wiring, disconnect switches and over current
protection must be supplied by the installer. Wire size should be sized per requirements.
CAUTION
All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance
with Local, National Fire, Safety & Electrical Codes. This unit must be grounded
with a separate ground wire in accordance with the above codes.
The complete connection diagram and schematic wiring label is located on the inside
surface of the unit service access panel and this instruction.
6.2 FIELD CONNECTIONS POWER WIRING
1. Install the proper size weatherproof disconnect switch outdoors and within sight of
the unit.
2. Remove the screws at the side of the corner panel. Slide corner panel down and
remove from unit. See Fig. 9.
3. Run power wiring from the disconnect switch to the unit.
4. Route wires from disconnect through power wiring opening provided and into the
unit control box.
5. Install the proper size time-delay fuses or circuit breaker, and make the power
supply connections.
6. Energize the crankcase heater if equipped to save time by preheating the compressor oil while the remaining installation is completed.
NOTE: When changing the motor, remove top cover first.
CORNER
PANEL
HIGH VOLTAGE WIRING
LOW VOLTAGE WIRING
Fig.9 Typical Field Wiring
14
6.3 REMOVING THE TOP PANEL AND MOTOR
1/2” nut
NOTE:
Damage will occur to condenser unit
if you remove fan nuts prior to cover removal.
5/16” nuts
Fig.10 COVER AND FAN
When motor requires changing follow the steps below:
Step 1: Go into electrical panel, disconnect motor power lines.
IMPORTANT NOTE
Disconnect main power to unit. Severe burns and electrical shock will occur if
you do not disconnect main power.
Step 2: Remove cover (be careful of motor wires)
Step 3: Be sure to place fan cover unit on the ground as indicated in Fig. 10
IMPROTANT NOTE
Do not place or lean fan blades on ground or against surface.
Step 4: Remove fan motor by removing 5/16” nuts from cover.
Step 5: Remove fan blade from motor by removing 1/2” nut and place fan on the ground.
Step 6: Reverse removal process to reinstall the fan and motor.
IMPROTANT NOTE
When connecting motor wires be sure to check motor direction.
7.0 SYSTEM OPERATION
7.1 COMPRESSOR CRANKCASE HEATER (CCH) (Heat pump only,optional)
Refrigerant migration during the off cycle can result in a noisy start up. Add a crankcase
heater to minimize refrigeration migration, and to help eliminate any start up noise or
bearing “wash out”.
All heaters must be located on the lower half of the compressor shell. Its purpose is to
drive refrigerant from the compressor shell during long off cycles, thus preventing
damage to the compressor during start-up.
At initial start-up or after extended shutdown periods, make sure the heater is energized
for at least 12 hours before the compressor is started. (Disconnect switch on and wall
thermostat off.)
The crankcase heating start condition:
1.The crankcase heating start must meet two conditions:
A. Outdoor temperature <37.4° F.
B. Compressor stops working more than 3 hours.
2. Outdoor temperature <37.4° F and just connected to the power source.
The crankcase heating stop must meet condition:
Outdoor temperature >44.6° F or compressor start.
7.2 REVERSING VALVE INTRODUCTION (Heat pump only)
Reversing valve energizes at the heating conditions, and cut off at the cooling condition.
15
7.3 PROTECTION FUNCTION INTRODUCTION (Heat pump only)
Sensor T3 (condenser pipe temperature) and T4 (outdoor ambient temperature)
When open-circuit, compressor, outdoor fan motor and reverse valve will be OFF.
T3>149°F,compressor stop working ; T3<140°F,compressor start working.
When T4 < 5 °F, compressor will stop.If the electrical heater kit is installed in the
indoor unit, the outdoor unit would provide a signal to drive up the heater.
When T4 > 10.4 °F, compressor will restart.
Discharge temperature protection (optional)
When discharge temp. > 275 °F, the compressor will stop.
When discharge temp. < 194 °F, the compressor will restart.
High pressure protection (optional)
When high pressure > 638 PSIG, the compressor and outdoor fan motor will stop.
When high pressure < 464 PSIG, the compressor and outdoor fan motor will restart
(3 minutes delay necessary).
Low pressure protection
Low pressure < 21 PSIG, the compressor and outdoor fan motor will stop.
Low pressure > 44 PSIG, the compressor and outdoor fan motor will restart
(3 minutes delay necessary).
In stand-by status, the compressor will not start in low pressure protection.
Within 30 mins, if 4 protection cycles occurs.The system will be locked. It will
be restore after power cycle.
7.4 DEFROST MODE INTRODUCTION (Heat pump only)
Start-up conditions of defrost mode:
When JUMP switch is set to “1”(See in Fig 11), the mode will start up in either of
the two following conditions:
1. Compressor operating, when T4 is > 28.4 °F and T3 is < 32 °F last for 40 minutes;
2. Compressor operating, when T4 is < 28.4 °F and T3 is < 32 °F last for 50 minutes.
When JUMP switch is set to “0”:
Compressor operating, when T3 is < 32 °F last for 30 minutes.
Shut-down conditions of defrost mode:
The mode will shut down in either of the two following conditions:
1. The defrosted time lasting for 10 minutes;
2. T3 is ≥ 77 °F.
JUMP Switch
Fig.11 JUMP Switch Location in the PCB Board
Troubleshooting see TABLE4
16
8.0 CHECKING REFRIGERANT CHARGE
Charge for all systems should be checked against the Charging Chart inside the
access corner panel or Charging by weight.
IMPORTANT:Do not operate the compressor without charge in system. Addition of
R-410A will raise pressures (suction, liquid and discharge).
8.1 CHARGING BY LIQUID PRESSURE
In order to properly charge the system, the following conditions must be met:
1) Outdoor temperature above 60°F.
2) Indoor temperature between 70°F to 100°F.
3) Installation must be complete with brazed joints and drier visually inspected.
4) The unit electrical installation must be checked and unit powered for one (I) hour if
crank case heater is used or five (5) minutes if no crankcase heater is used.
Follow these steps:
1. Run in cooling mode at least 10 minutes.
2. Measure OUTDOOR AMBIENT TEMPERATURE within 6 inches of coil.
3. Measure SUCTION LINE PRESSURE.
4. Find the TARGET LIQUID PRESSURE at the intersection between the SUCTION
LINE PRESSURE and the OUTDOOR AMBIENT TEMPERATURE, if falls between
rows or columns then estimate the TARGET LIQUID PRESSURE or SUCTION LINE
PRESSURE falls between rows or columns then estimate the TARGET LIQUID
PRESSURE between the rows and columns.
5. Compare the measured LIQUID LINE PRESSURE to the TARGET LIQUID
PRESSURE, add charge to raise the pressure or recover charge to lower it.
6. After running unit for 10 minutes if the SUCTION LINE PRESSURE changes, go
back to step 2 otherwise remove test equipment and cover the valves.
8.2 CHARGING BY WEIGHT
For a new installation,evacuation of interconnecting tubing and indoor coil is adequate;
otherwise,evacuate the entire system. The factory refrigerant charge in the outdoor
unit is sufficient for 15 feet of standard size interconnecting liquid line. Calculate
actual charge required with installed liquid line size and length,please see 4.1 of
instruction.
With an accurate scale (+/- 1 oz.) adjust charge difference between that shown on
the unit data plate and that calculated for the new system Installation. if the entire
system has been evacuated, add the total calculated charge.
8.3 FINAL LEAK TESTING
After the unit has been properly evacuated and charged, a halogen leak detector
should be used to detect leaks in the system. All piping within the condensing unit,
evaporator, and interconnecting tubing should be checked for leaks. If a leak is
detected, the refrigerant should be recovered before repairing the leak. The Clean Air
Act prohibits releasing refrigerant into the atmosphere.
17
9.0 WARRANTY
Assist owner with processing Warranty cards and/or online registration.
9.1 MAINTENANCE
1.. Dirt should not be allowed to accumulate on the indoor or outdoor coils or other parts
in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush,
vacuum cleaner attachment, or other suitable means.
2. The outdoor fan motor is permanently lubricated and does not require periodic oiling.
3. Refer to the furnace or air handler instructions for filter and blower motor maintenance.
4. The indoor coil and drain pan should be inspected and cleaned regularly to assure
proper drainage.
CAUTION
It is unlawful to knowingly vent, release or discharge refrigerant into the open air
during repair, service, maintenance or the final disposal of this unit. When the
system is functioning properly and the owner has been fully instructed, secure the
owner’s approval.
10.0 WIRING DIAGRAM
CAUTION
These units must be wired and installed in accordance with all National and
Local Safety Codes.
10.1 CONTROL WIRING FOR A/C UNITS
CC
COMP
RC 1
RC 2
RC 3
COMPRESSOR CONTACTOR
COMPRESSOR
RUN CAPACITOR 1
RUN CAPACITOR 2
RUN CAPACITOR 3
L1
BLACK
LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
L1
L2
L2
CC
A2
A1
C
Y
BLACK
YEL LOW
LOW VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY
BLACK
C
BLACK
GREEN
WHITE OR YELLOW
RC 1
S
COMP
WARNING :
CABINET MUST BE PERMANMENTLY GROUNDED
AND ALL WIRING TO CONFORM TO I.E.C, N.E.C,
C.E.C, C.L.C, AND LOCAL CODES AS APPLICABLE
REPLACEMENT WIRE MUST BE THE SAME GAUGE
AND INSULATION TYPE AS ORIGINAL WIRE.
ORANGE
F AN
R
BL ACK
BL ACK
RC 3
RED
RC 2
BL ACK
GREEN
BROWN
Fig.12 Outdoor Unit Wiring Diagram for A/C Systems (208/230V 1P 60Hz).
(exclude LG compressor systems)
18
HGS
HOT GAS OR COMPRESSOR TOP SENSOR
CC
COMPRESSOR CONTACTOR
COMP COMPRESSOR
RC 1
RUN CAPACITOR 1
RC 2
RUN CAPACITOR 2
RC 3
RUN CAPACITOR 3
L1
L2
BLACK
CC
LINE VOLTAGE
FAC TORY STAN DARD
FIELD INSTALLED
FAC TORY OPT IONAL
A2
A1
BLACK
C
Y
HGS
YELLOW
LOW VOLTAGE
FAC TORY STAN DARD
FIELD INSTALLED
FAC TORY OPT IONAL
USE COPPER C ONDUCTO RS ONLY
YELLOW
GREEN
BLACK
BLACK C
GND
ORANGE
COMP
RC 1
WAR NING:
CAB INET MUST BE PERM ANMENTLY
GOU NDED AND ALL WIRIN G TO CON FORM TO
I.E.C ,N.E.C,C.E .C,C.L.C,AN D LOCAL CODES AS APPLICAB LE
REP LACEMENT WIRE MU ST BE THE SAM E GA UGE AND
INSU LATION TYPE AS O RIGINAL W IRE
FAN
R
S
WHITE OR YEL LOW
BLACK
GND
RC 2
GREEN
BL ACK
BROWN
RED
BLACK
RC 3
Fig.13 Outdoor Unit Wiring Diagram for A/C Systems (208/230V 1P 60Hz).
(just for LG compressor systems)
THERMOSTAT
C
R
G
R
C
INDOOR UNIT
Y
BLACK
LACK
YELLO W
BLACK
LACK
R ED
D
G
GREEN
N
Y
C
OUTDOOR UNIT
Fig.14 Control Wiring for A/C Systems.
19
10.2 CONTROL WIRING FOR H/P UNITS
CC
CCH
COMP
DFC
T4
T3
HPC
LPC
OFM
RC 1
RC 2
RC 3
RV
GND
HGS
COMPRESSOR CONTACTOR
CRANKCASE HEATER
COMPRESSOR
DEFROST CONTROL
AMBIENT TEMPERATURE
PIPE TEMPERATURE
HIGHT PRESSURE CUT-OUT CONTROL
LOW PRESSURE CUT-OUT CONTROL
OUTDOOR FAN MOTOR
RUN CAPACITOR 1
RUN CAPACITOR 2
RUN CAPACITOR 3
REVERSING VALVE
GROUND CHASSIS
HOT GAS SENSOR
LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
LOW VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY
WARNING :
CABINET MUST BE PERMANMENTLY
GROUNDED AND ALL WIRING TO CONFORM TO
I.E.C, N.E.C, C.E.C, C.L.C, AND LOCAL CODES AS
APPLICABLE REPLACEMENT WIRE MUST BE THE SAME
GAUGE AND INSULATION TYPE AS ORIGINAL WIRE.
Fig.15 Outdoor Unit Wiring Diagram for H/P Systems(208/230V 1P 60Hz).
W2
B
C
R
Y
w1
INDOOR UNIT
R
C
PURPLE
BLUE
Y
B
OUTDOOR UNIT
Fig.16 Control Wiring for H/P Systems.
20
YELLOW
BLACK
C
RED
R
WHITE
BLACK
G
RED
THERMOSTAT
GREEN
G
D
TABLE 4. Troubleshooting
EF.
RD
SO
F.
SEN R DE
O
GS
S
F.
E
EN
C/H
H P P. S SOR D .
EF
EM SEN
LD
T3 T
.
O
P
N T R EF.
T EM
T4 ST CO SOR D
G
RO
EN
KIN
D E F L PC S
LEA
VE CTIVE
VAL
E
CK
DEF NG
CHE COIL LEAKI
S
SOV SOV CTION
T R I OW
RES AIRFL
IR.
. C . I.D. RHEAT
S
REF
E
E
R
SUP OPEN
CK
N
STU ATIO
TXV RCUL W
FLO
ECI
R R .D. AIR LES
. AI
B
O.D RES. O ENSA D
ND
L OA
NCO AP.
NO E EV ARGE
H
IV
ESS
ERC GE
EXC EF. OV CHAR .
R
P
R
NDE T COM
.U
REF CIEN SSOR
E
FFI
INE OMPR USE
F
C
CK
IL
AG E
STU VOLT R CO
O
LOW TACT STAT
O
N
RM
CO
R
THE ORME
NSF IRING
TRA
W
OL
GE
TS
NTR VOLTA NTAC
CO
O
R
C
LOW TOR ACITO
C CAP
OR
NTA
CO OWER PACIT
A
R
BL
N C ACITO
I.D.
P
.
. FA
O.D R CA L DEF
SS RO
PRE ONT
ING
COM I.D. C E WIR Y
AG U P P L
OLT
S
E
H V ER
H I G P OW K M O D
C
CHE
TO
AT
WH
SYSTEM FAULTS
REFRIGERANT CIRCUIT
Head Pressure Too High
Head Pressure Too Low
Suction Pressure Too High
Suction Pressure Too Low
Liquid Refrig. Floodback
(TXV)
I.D. Coil Frosting
Compressor Runs Inadequate or
No Cooling/Heating
P P S P S
P P S
C
H
C
H
C
H
C
H
C
H
C
H
C
H
S P
S P
P P
S
S
P
P
P
S P
S P
S
P S
S S
S S
S S S
S S
P
S
P
S
S P S
S
S S
S
S
P
P
S S
P
P
P
P
P
S
S P S S
S P S S S S
S S
S
ELECTRICAL
C
H
C
Compressor Will Not Start But
O.D. Fan Runs
H
C
O.D. Fan Won’t Start
H
C
Compressor Hums But Won’t Start
H
C
I.D. Blower Won’t Start
H
DEFROST
C
Unit Won’t Initiate Defrost
H
C
Defrost Terminates on Time
H
C
Unit Icing Up
H
Compressor & O.D. Fan Won’t Start
P P
P P
P
P
P
P
S
P
P
P
S
S S
P
P
S S S
S
P
P
S
S
S
S
P
P
P P S
P P S
S P S P P
S P S
P
P
P
P
P
S P S
S P S
S
S
P
P
P
S S
S
P
P
S
P
S
P
C- Cooling H - Heating P - Primary Causes S - Secondary Causes
TABLE 5. Operational And Checkout Procedures
Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance,
all units must be operated and charge adjustments made in accordance with procedures found in the Service Facts
of the Outdoor Unit.
After installation has been completed, it is recommended that the entire system be checked against the following list:
1. Be sure unit suspension(if used) is secure and that
thereare no tools or loose debris in or around or on
top of the unit...................................................... [ ]
2. Properly insulate suction lines and fittings. ......... [ ]
3. Properly secure and isolate all refrigerant lines... [ ]
4. Verify that all electrical connections are tight. ..... [ ]
5.Check all duct outlets; they must be open and unrestricted. [ ]
6.Check drain lines and be sure all joints are tight............... [ ]
7.Be sure that a return air filter is installed. .......................... [ ]
8.Operate complete system in each mode to verify proper
performance. Verify operation of supplementary electric
heater. ............................................................................... [ ]
21
TABLE 6: Electrical Data:
Model
18AC/T
18HP/T
24/T
30/T
18/C
24AC/C
30AC/C
24HP/C
30HP/C
36/C
42/C
48/C
60/C
18/L
24/L
30/L
36/L
42/L
48/L
60/L
Minimum Circuit Ampacity(A)
9.0
9.4
11.6
16.0
11.9
17.6
18.4
17.5
18.7
21.9
24.1
29.0
34.7
11.9
14.4
15.2
20.2
28.2
32.0
31.1
Maximum Circuit Protector(A)
15
15
20
25
20
30
30
30
30
35
40
50
60
20
25
25
35
45
50
50
NOTES: 1.AC: Air Conditioner; HP: Heat Pump; No description:Air Conditioner & Heat Pump.
2.T: Toshiba Compressor; C: Copeland Compressor; L: LG Compressor
22
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